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Engine Electrical System (D4FA - DSL1.5) : General Charging System Starting System
Engine Electrical System (D4FA - DSL1.5) : General Charging System Starting System
System(D4FA DSL1.5)
GENERAL
CHARGING SYSTEM
ALTERNATOR
BATTERY
STARTING SYSTEM
STARTER
STARTER RELAY
PREHEATING SYSTEM
EEA -2
GENERAL
SPECIFICATION
E63F15E2
STARTING SYSTEM
Items
Specification
Rated voltage
12 V, 1.7 kW
No-load
characteristics
Starter
Commutator diameter
Voltage
11 V
Ampere
90A, MAX
Speed
Standard
29.4 mm (1.1575in.)
Limit
28.8 mm (1.1339in.)
Standard
0.5 mm (0.0197in.)
Limit
0.2 mm (0.0079in.)
CHARGING SYSTEM
Items
Alternator
Battery
Specification
Type
Rate voltage
12 V, 120A
Speed in use
Voltage regulator
14.55 0.2 V
Temperature compensation
-7 3 mV / C
Type
MF 68AH
600 A
Reserve capacity
110 min
1.280 0.01
NOTE
COLD CRANKING AMPERAGE is the amperage
a battery can deliver for 30 seconds and maintain
a terminal voltage of 7.2V or greater at a specified
temperature.
RESERVE CAPACITY RATING is amount of time
a battery can deliver 25A and maintain a minimum terminal voltage of 10.5V at 26.7 C(80.1 F).
GENERAL
TROUBLE SHOOTING
EEA -3
E81C5D80
STARTING SYSTEM
Symptom
Engine will not crank
Suspect area
Remedy
Starter motor
Ignition switch
Replace
Replace
Short in wiring
Pinion gear teeth broken or starter motor
Ring gear teeth broken
Repair wiring
Replace
Replace fly wheel or torque converter
Replace
CHARGING SYSTEM
Symptom
Suspect area
Remedy
Fuse blown
Light burned out
Wiring connection loose
Electronic voltage regulator
Check fuses
Replace light
Tighten loose connection
Replace voltage regulator
Overcharge
Discharge
Fuse blown
Electronic voltage regulator or alternator
Poor grounding
Worn battery
EEA -4
CHARGING SYSTEM
DESCRIPTION
ON-VEHICLE INPECTION
E52DA296
CAUTION
ECD624A6
Brush
2.
Turn the ignition switch OFF and turn off the electrical
systems.
3.
Rectifier
Stator
Rotor
1.
2.
2.
Check that there is no abnormal noise from the alternator while the engine is running.
2.
3.
Turn the ignition switch "ON". Check that the discharge warning light is lit.
4.
CHARGING SYSTEM
EEA -5
TEST
1.
2.
RESULT
PREPARATION
1.
1.
2.
Disconnect the output wire from the alternator "B" terminal. Connect the (+) lead wire of ammeter to the
"B" terminal of alternator and the (-) lead wire of ammeter to the output wire. Connect the (+) lead wire of
voltmeter to the "B" terminal of alternator and the (-)
lead wire of voltmeter to the (+) terminal of battery.
Alternator
Ammeter
Voltmeter
Battery
BBGE002A
3.
EEA -6
TEST
1.
2.
3.
PREPARATION
1.
2.
3.
4.
Disconnect the alternator output wire from the alternator "B" terminal.
5.
NOTE
After the engine start up, the charging current quickly
drops. Therefore, the above operation must be done
quickly to read the maximum current value correctly.
RESULT
1.
NOTE
NOTE
Connect a voltmeter (0 to 20V) between the "B" terminal and ground. Connect the (+) lead wire to the alternator "B" terminal and (-) lead wire to a good ground.
7.
8.
Voltmeter Ammeter
Ioad
2.
3.
4.
5.
6.
Check engine
L
S or DUMMY
LBGF002A
CHARGING SYSTEM
EEA -7
TEST
The purpose of this test is to check that the electronic voltage regulator controls voltage correctly.
1.
PREPARATION
1.
If it reads 0V, there is an open circuit in the wire between the alternator "B" terminal and the battery and
the battery (-) terminal.
2.
3.
2.
3.
RESULT
4.
1.
5.
Disconnect the alternator output wire from the alternator "B" terminal.
6.
7.
-20 (-4)
20 (68)
60 (140)
80 (176)
Voltmeter Ammeter
14.2
14.0
13.7
13.5
~
~
~
~
15.4
15.0
14.9
14.7
3.
4.
5.
6.
Check engine
LBGF002A
2.
Ioad
L
S or DUMMY
EEA -8
ALTERNATOR
REPLACEMENT
E32558EE
1.
2.
LCGF119A
3.
Tightening torque :
38.2 ~ 58.8N.m (3.9 ~ 6.0kgf.m, 28.2 ~ 43.4lbf.ft)
LCGF005A
4.
CHARGING SYSTEM
COMPONENT
EEA -9
EBE188A8
23
7
6
21
20
4
16
22
19
12
18
17
11
10
15
14
13
1.
2.
3.
4.
5.
6.
7.
8.
Nut
Pulley
Bushing
Front cover assembly
Stator coil
Front bearing
Front bearing cover
Front bearing cover bolt
9.
10.
11.
12.
13.
14.
15.
16.
Rotor coil
Rear bearing
Rear bearing cover
Damper
Packing
Rear cover
Through bolt
Seal
17.
18.
19.
20.
21.
22.
23.
Rectifier assembly
Brush holder assembly
Brush holder bolt
Stud bolt
Guard
Cover
Cover nut
LBGF037A
EEA -10
DISASSEMBLY
1.
4.
EE5DAE6A
A
B
LBGF005A
5.
LCGF120A
2.
SST(09373-27000)
LBGF006A
6.
LBGF003A
3.
B
A
LCGF121A
LBGF004A
CHARGING SYSTEM
7.
EEA -11
INSPECTION
E1D4E7FD
INSPECT ROTOR
1.
A
LBGF007A
8.
C
B
A
LBGF009A
2.
3.
INSPECT STATOR
1.
B
A
LBGF008A
9.
LBGF010A
2.
3.
EEA -12
BATTERY
DESCRIPTION
EF8FBD2E
1.
2.
3.
EBJD008A
CHARGING SYSTEM
INSPECTION
EEA -13
EC7F1CDF
OK
Below 11.0V
Replace battery
Above 12.5V
OK (11.0 ~ 12.4V)
Charge battery
OK
Battery is good
LBGF011A
EEA -14
LOAD TEST
1.
1.
2.
2.
1)
3.
2)
3)
4)
5)
Temperature
9.6V
9.5V
16 C (60.8 F)
9.4V
10 C (50.0 F)
9.3V
4 C (39.2 F)
9.1V
-1 C (30.2 F)
8.9V
-7 C (19.4 F)
8.7V
-12 C (10.4 F)
8.5V
-18 C (-0.4 F)
CAUTION
Care should be taken in the event the battery case
is cracked or leaking, to protect your skin from the
electrolyte.
Heavy rubber gloves (not the household type)
should be wore when removing the battery.
EBJD008B
4.
5.
6.
7.
8.
9.
NOTE
-
If
10. Connect the cable terminals to the battery post, making sure tops of the terminals are flush with the tops
of the posts.
CHARGING SYSTEM
EEA -15
EBJD008A
EEA -16
STARTING SYSTEM
DESCRIPTION
STARTER CIRCUIT
TROUBLESHOOTING
E9CCB56A
E6CD00C1
NOTE
The starting system includes the battery, starter, solenoid
switch, ignition switch, inhibitor switch (A/T), ignition lock
switch, connection wires and the battery cable.
When the ignition key is turned to the start position, current
flows and energizes the starter motors solenoid coil.
The solenoid plunger and clutch shift lever are activated,
and the clutch pinion engages the ring gear.
The contacts close and the starter motor cranks. In order
to prevent damage caused by excessive rotation of the
starter armature when the engine starts, the clutch pinion
gear overruns.
Solenoid
ABGE002A
2.
Brush assembly
Armature
Overrun clutch
LBGF012A
If it wont disengage from the ring gear when you release key, check for the following until you find the
cause.
Solenoid plunger and switch malfunction.
Dirty pinion gear or damaged overrunning clutch.
3.
Check the battery condition. Check electrical connections at the battery, battery negative cable connected
to the body, engine ground cables, and the starter for
looseness and corrosion. Then try starting the engine
again.
If the starter cranks normally the engine, repairing the
loose connection repaired the problem. The starting
system is now OK.
If the starter still does not crank the engine, go to next
step.
4.
Disconnect the connector from the S-terminal of solenoid. Connect a jumper wire from the B-terminal of
solenoid to the S-terminal of solenoid.
If the starter cranks the engine, go to next step.
If the starter still does not crank the engine, remove
the starter, and repair or replace as necessary.
STARTING SYSTEM
5.
EEA -17
STATER SOLENOID TEST
1.
2.
B
M
Starter
motor
12V
BBGE004A
3.
4.
5.
6.
EEA -18
STARTER
2.
3.
REPLACEMENT
1.
2.
S
M
EFC90D5C
Corbon-pile rheostat
Ammeter
A
Starter
motor
V Voltmeter
Battery
12V
A
B
LCGF122A
BBGE005A
4.
5.
6.
7.
3.
4.
5.
STARTING SYSTEM
COMPONENT
EEA -19
E9B18E5C
14
6
7
4
1
13
12
11
10
15
9
5
3
2
20
19
18
17
16
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
Screw
Front bracket assembly
Stop ring
Stopper
Overrun clutch assembly
Lever
Plate
Lever packing
Internal gear assembly
Planet shaft assembly
11.
12.
13.
14.
15.
16.
17.
18.
19.
20.
EEA -20
DISASSEMBLY
1.
4.
E3BDCF91
LBGF017A
LBGF014A
2.
5.
A
B
A
B
LBGF018A
6.
LBGF015A
3.
LBGF019A
LBGF016A
STARTING SYSTEM
7.
EEA -21
8.
LBGF020A
LBGF023A
11. Disconnect the stop ring(A), overrunning clutch(B), internal gear(C) and planet shaft(D).
B
D
B
A
A
LBGF021A
LBGF024A
9.
LBGF022A
EEA -22
EB74B9B5
NOTE
Using a suitable pulling tool(A), pull the overrunning
clutch stop ring(B) over the stopper(C).
1.
2.
3.
Inspect the armature for wear or damage from contact with the permanent magnet. If there is wear or
damage, replace the armature.
LBGF025A
LBGF026A
4.
LBGF027A
STARTING SYSTEM
5.
EEA -23
7.
Commutator diameter
Standard (New) : 29.4 mm (1.1575 in)
Service limit : 28.8 mm (1.1339 in)
D
B
A
LBGF028A
6.
LBGF030A
8.
Commutator runout
Standard (New) : 0.02mm (0.0008in.) max
Service limit : 0.05mm (0.0020in.)
LBGF031A
LBGF029A
EEA -24
9.
Check with an ohmmeter that no continuity exists between the commutator(A) and armature coil core(B),
and between the commutator and armature shaft(C).
If continuity exists, replace the armature.
A
B
A
LBGF032A
EBBD330A
1.
2.
Limit line
LBGF033A
LBGF034A
3.
STARTING SYSTEM
CLEANING
1.
2.
3.
EEA -25
STARTER RELAY
INSPECTION
E4DA1682
1.
2.
ABGE018A
3.
4.
Continuity
30 - 87
NO
85 - 86
YES
LDAD510B
5.
6.
7.
EEA -26
PREHEATING SYSTEM
COMPONENT
E5D24EED
0.8 ~ 1.5
(0.08 ~ 0.15, 0.6 ~ 1.1)
3
15 ~ 20
(1.5 ~ 2.0, 11 ~ 14)
3. Glow plug
LCGF123A
PREHEATING SYSTEM
INSPECT PREHEATING SYSTEM
EEA -27
E6757D67
2.
3.
CAUTION
Remove oil from plug before measuring as glowplug resistance is very small.
2.
3.
NOTE
Continuity time varies depending upon cooling water
temperature.
4.
5.
6.
EBKD300O
EBKD300P
EEA -28
2.
2
1
5
4
LBGF035A
3.
2
1
5
4
LBGF036A
4.